Ceramic Hang Capstone Print Packet

Generated: 2026-05-06

Packet folder: `/mnt/c/Users/Tony/Documents/GitHub/ceramic-hang`

File Map

design.md

Project intent, catalog metadata, assumptions, and validation plan.

Ceramic Hang Design

Design Intent

Design a slip-cast ceramic, handpan-inspired tonal vessel that explores raised/isolated ceramic tone fields on a shallow resonant shell. The project is a research instrument first: the goal is to learn whether molded ceramic tone fields can produce musically useful fundamentals and partials after firing, and what clay body, wall thickness, tone-field geometry, and firing schedule make that repeatable.

The visual target is an approachable 18 inch handpan-like form, but the engineering target is more careful: a ceramic tonal vessel whose final design may diverge from steel handpans if the material asks for a different geometry.

Governing Model

This instrument is governed by coupled plate/shell vibration plus Helmholtz body resonance.

tone_field_f1 ~= (kappa / (2*pi)) * (h / a^2) * sqrt(E / (rho * (1 - nu^2)))

Where `h` is local tone-field thickness, `a` is effective field radius, `E` is Young's modulus, `rho` is density, `nu` is Poisson ratio, and `kappa` is an empirical boundary/shape coefficient. For ceramic this equation is a sanity check, not a final predictor.

f_gu = c/(2*pi) * sqrt(A_gu / (V_shell * L_eff_gu))
L_eff_gu = wall + 0.6 * sqrt(A_gu/pi)

The gu/port resonance should be measured as a coupled body mode. It may support warmth and sustain, but it will not tune the tone fields the way hammered steel tuning does.

Design Targets

Target Note Layout

The note layout is intentionally marked as an assumption. Ceramic fields may prefer fewer larger notes, different intervals, or a tongue/slit hybrid if isolated plate fields do not ring cleanly.

Manufacturing Strategy

Use a slip-cast two-shell body:

1. CAD an upper dome with raised tone-field islands and a lower shell with gu port.

2. 3D print master positives oversized by measured clay shrinkage.

3. Make plaster molds with clean registration and no trapped undercuts.

4. Slip cast upper and lower shells separately.

5. Join at leather-hard stage with a reinforced rim/luting band.

6. Bisque fire before any glaze commitment.

7. Measure tone fields, body modes, gu resonance, cracks, and distortion.

8. Iterate field thickness, island geometry, and clay body before decorative finishing.

Prototype Ladder

Empirical Questions

• What clay body gives the longest decay without excessive fragility?
• Do raised tone fields, thinned tone fields, or cut/relief-bounded fields speak best?
• Does glaze damp the fields too much?
• Can tone fields be tuned at greenware/leather-hard stage accurately enough to survive firing?
• Is a 9-note layout realistic in ceramic, or should the first product be 5-7 notes?
• Should the final instrument become a ceramic tongue-handpan hybrid instead of a pure tone-field shell?

Assumptions And Unknowns

• Elastic properties are derived estimates until test bars are fired and measured.
• No empirical ceramic handpan correction data exists yet in this repo.
• The screenshot reference is visual inspiration only; no supplier dimensions or pricing are used as source data.
• Final tuning may require new mold masters rather than post-fire correction.
• Structural safety matters: the instrument must survive hand strikes, thermal gradients, and transport.

bom.csv

Starter bill of materials with part categories, quantities, drawing refs, and notes.

sourcing.csv

Supplier/search tracker with specs, price/date fields, lead time, substitutes, and risks.

cut-list.csv

Rough/final stock sizes, material, grain/orientation, operations, yield, and offcuts.

drawing-brief.md

Manufacturing drawing and technical product sketch brief.

Ceramic Hang Drawing Brief

Required Views

• Top view with center ding, outer tone-field layout, note labels, field axes, and radial datum.
• Side section through center showing upper dome, lower shell, rim seam, wall thickness, and gu.
• Tone-field detail showing raised/thinned field geometry, relief boundary, thickness target, and strike zone.
• Bottom view showing gu diameter, lower shell curvature, support/rim datum, and optional feet or stand interface.
• Mold split view showing upper mold, lower mold, registration, cottle clearance, and release directions.
• Firing support view showing setter/ring contact areas and shrinkage clearance.

Critical Dimensions

CAD Notes

• Mark all values as fired dimensions or master dimensions.
• Keep tone-field geometry as named parameters.
• Add build ID and CAD revision to every drawing.
• Do not hide the `TBD` status of ceramic material constants.
• Include a validation table once measured data exists.

assembly-manual.md

Shop-facing sequence, tools, fixtures, safety, tuning, finishing, and maintenance notes.

Ceramic Hang Assembly Manual

Scope

This manual covers the first ceramic handpan-inspired tonal vessel prototypes. It assumes the instrument is slip-cast from upper and lower shell molds and validated as a research build before decorative finishing.

Tools And Setup

• CAD model for upper shell, lower shell, tone-field islands, gu, rim, and mold split.
• Large-format 3D printer or outsourced print service.
• Plaster mold-making setup: cottle boards, scale, bucket, plaster, mold release, clamps.
• Cone 6 casting slip and known firing schedule.
• Drying cradle and firing support ring.
• Calipers, scale, tuner, microphone, recording app, and spreadsheet/validation log.
• Diamond files/burrs for minimal cleanup.
• Kiln access.

Process

1. **Make shrinkage bars**

- Cast or form test bars from the actual clay body.

- Fire through the intended bisque and glaze schedule.

- Replace the assumed 12 percent shrinkage with measured data before final master printing.

2. **Build tone coupons**

- Make small raised/thinned field coupons before a full shell.

- Vary thickness, field diameter, relief depth, and clay body.

- Record pitch, decay, cracking, and perceived strike feel.

3. **Model the first shell**

- Model the fired target geometry first.

- Apply `master_scale_factor = 1/(1 - shrinkage)`.

- Keep the first upper shell conservative: fewer undercuts, larger radii, and enough wall thickness to survive handling.

4. **Print and seal masters**

- Print upper and lower shell masters or segments.

- Fill segment seams, sand, and seal.

- Mark centerline, tone-field index, rim datum, and gu center.

5. **Make plaster molds**

- Build cottle boxes with enough plaster thickness for a large dome.

- Include registration and mold handling features.

- Dry molds fully before slip casting.

6. **Slip cast shells**

- Cast upper and lower shells separately.

- Record slip batch, pour time, drain time, demold time, room condition, and measured wall thickness.

- Support shells in a cradle as they stiffen.

7. **Join and refine**

- Join upper/lower shells at leather-hard stage.

- Smooth seam and rim.

- Keep post-join tone-field carving minimal and documented.

8. **Dry slowly**

- Dry under plastic with frequent inspection.

- Watch tone-field edges, gu, rim seam, and support contact points.

9. **Bisque fire and measure**

- Fire to the clay body's recommended bisque schedule.

- Measure every tone field and the gu/body resonance before glazing.

- Decide whether to continue, revise the mold, or return to coupons.

10. **Finish test**

- Test glaze or oxide on coupons before the full body.

- If glazing the full shell, leave tone-field strike zones and acoustic edges as controlled test variables.

11. **Final validation**

- Record pitch, cents error, decay time, body mode, gu response, crack status, and playability.

- Feed results back into the next design table revision.

Shop Notes

• Do not chase final tuning on the first shell. The first shell is a measurement object.
• Never grind aggressively on fired tone fields.
• Add a protective rim strategy early; ceramic rims are vulnerable.
• Treat transport as a design requirement, not an afterthought.

validation.csv

Target/measured values, tolerance, environment, result, and tuning/build action log.

supplier-rfq.md

Supplier email/request-for-quote starter.

Supplier RFQ - Ceramic Hang

Subject: RFQ - materials and services for slip-cast ceramic tonal vessel prototype

Hello,

I am prototyping an 18 inch slip-cast ceramic tonal vessel and need pricing/lead time for the following items or services:

• Cone 6 stoneware or porcelain casting slip with published shrinkage and firing schedule.
• #1 pottery plaster or equivalent pottery mold plaster, 75 lb class quantity.
• Optional large-format 3D print service for an 18-20 inch dome master, or segmented master parts.
• Kiln-safe refractory support material or custom setter/ring options.
• Optional padded case suitable for a fragile 18 inch ceramic handpan-style object.

Please include:

• Unit price and quantity breaks.
• Current availability and lead time.
• Shipping estimate to Santa Clara, CA.
• Technical data sheet or material specification.
• Recommended substitutes if the exact item is unavailable.

Notes:

• Shrinkage and firing schedule are critical.
• The first run is prototype/research scale, not production volume.
• If substitutions are proposed, please include material compatibility and firing temperature notes.

Thank you,

Tony Koop

visual-bom-brief.md

Art direction for an image-forward visual BOM.

Ceramic Hang Visual BOM Brief

Goal

Create an image-forward one-page visual BOM that explains the ceramic handpan workflow at a glance: digital master, plaster mold, cast shells, tone fields, support fixtures, finishing, and measurement tools.

Layout

• Header: "Ceramic Hang - Slip-Cast Tonal Vessel Research Build".
• Hero image: CAD/render or finished prototype clearly labeled as concept/prototype.
• Process strip: tone coupons -> master print -> plaster molds -> greenware shell -> bisque measurement -> final finish.
• BOM table: item number, material/tool, quantity, spec, make/buy, cost/date status, image.
• Physics inset: plate/tone-field model plus gu Helmholtz model.
• Validation inset: field ID, target note, measured pitch, decay, crack status.

Required Images

• Upper shell CAD/render.
• Lower shell/gu CAD/render.
• Tone coupon test set.
• Mold halves.
• Greenware shell in drying cradle.
• Firing support/ring.
• Measurement setup with mic/tuner.
• Finished or bisque prototype.

Generated images or CAD renders should be marked as placeholders until replaced by shop photos.

ceramic-hang-starter.wl

Wolfram starter for physics, optimization, visualization, and validation.

(* Ceramic Hang first-order physics starter *)

ClearAll["Global`*"];

(* Units: SI inside formulas unless noted. *)
c = 343; (* m/s *)

(* Ceramic material placeholders. Replace with measured test-bar data. *)
Eceramic = 45*10^9;       (* Pa, derived estimate *)
rhoCeramic = 2200;        (* kg/m^3, derived estimate *)
nuCeramic = 0.23;         (* Poisson ratio estimate *)
kappaDisk = 10.2;         (* boundary/shape coefficient estimate *)

plateHz[h_, a_, E_, rho_, nu_, kappa_] :=
  (kappa/(2*Pi))*(h/a^2)*Sqrt[E/(rho*(1 - nu^2))];

helmholtzHz[area_, volume_, neck_] :=
  (c/(2*Pi))*Sqrt[area/(volume*neck)];

centsError[measured_, target_] := 1200*Log[2, measured/target];
targetFreq[midi_] := 440*2^((midi - 69)/12);

(* G minor 9-note target layout. *)
notes = {
  {"Ding", "G3", 196.00, 0.1016},
  {"T1", "Bb3", 233.08, 0.0864},
  {"T2", "C4", 261.63, 0.0813},
  {"T3", "D4", 293.66, 0.0762},
  {"T4", "F4", 349.23, 0.0699},
  {"T5", "G4", 392.00, 0.0648},
  {"T6", "Bb4", 466.16, 0.0597},
  {"T7", "C5", 523.25, 0.0559},
  {"T8", "D5", 587.33, 0.0521}
};

(* Solve rough thickness for each field using the first-order plate model. *)
roughThickness[targetHz_, radiusM_] :=
  targetHz*(2*Pi)/kappaDisk*radiusM^2/Sqrt[Eceramic/(rhoCeramic*(1 - nuCeramic^2))];

thicknessTable = Table[
  {id, note, hz, radius, roughThickness[hz, radius]},
  { {id, note, hz, radius}, notes}
];

thicknessTable // TableForm

(* Gu estimate, using a 3.5 in port and rough 700 in^3 body volume. *)
inch = 0.0254;
guDiameter = 3.5*inch;
wall = 0.25*inch;
bodyVolume = 700*inch^3;
guArea = Pi*(guDiameter/2)^2;
guLeff = wall + 0.6*Sqrt[guArea/Pi];
guHz = helmholtzHz[guArea, bodyVolume, guLeff];

guHz

README.md

Project artifact.

Ceramic Hang

Slip-cast ceramic handpan-inspired tonal vessel: a research build for exploring whether a fired ceramic shell can produce playable handpan-like tone fields while retaining the sculptural freedom of 3D printed mold masters.

This is not a conventional steel handpan clone. Steel handpans rely on plastic forming, hammer tuning, and elastic plate behavior. Ceramic is brittle, damped, formulation-dependent, and mostly tunes before firing. This repo treats the idea honestly: first as an empirical acoustic study, then as a buildable instrument family if the test coupons speak.

Start Here

• [design.md](design.md) - design intent, governing model, target G minor layout, assumptions, prototype ladder.
• [Ceramic-Hang-Design.xlsx](Ceramic-Hang-Design.xlsx) - parametric design table for shell geometry, gu resonance, tone-field targets, and validation inputs.
• [bom.csv](bom.csv) - bill of materials.
• [sourcing.csv](sourcing.csv) - supplier/search tracker with date-check fields.
• [cut-list.csv](cut-list.csv) - print, mold, fixture, and ceramic blank preparation list.
• [assembly-manual.md](assembly-manual.md) - shop workflow from CAD master through fired validation.
• [validation.csv](validation.csv) - measurement log for tone fields, shell/gu coupling, shrinkage, and cracking.
• [risks.md](risks.md) - red-team risk register with verification tests.
• [drawing-brief.md](drawing-brief.md) - drawing/CAD requirements and critical dimensions.
• [visual-bom-brief.md](visual-bom-brief.md) - image-forward documentation plan.
• [ceramic-hang-starter.wl](ceramic-hang-starter.wl) - first-order plate + Helmholtz model starter.
• [cad/ceramic_hang_master.scad](cad/ceramic_hang_master.scad) - OpenSCAD starter for shell/mold concept geometry.

Concept

The first serious target is an 18 inch ceramic tonal vessel in a G minor 9-note layout:

• Center ding: G3.
• Outer tone-field targets: Bb3, C4, D4, F4, G4, Bb4, C5, D5.
• Bottom gu port: tuned near the low-body resonance, not used as a primary melodic note.
• Clay target: Cone 6 stoneware or porcelain casting slip, measured shrinkage required.
• Manufacturing path: 3D printed master -> plaster mold -> slip-cast upper/lower shells -> bisque test -> glaze strategy -> final validation.

Development Rule

Every prototype gets a build ID and a measured record. Ceramic handpan work will only become predictable if the measured data loops back into the next mold, thickness, tone-field, and firing choices.

Related Repos

• [handpan](../handpan) - conventional handpan design table placeholder.
• [ceramic-tongue-drum](../ceramic-tongue-drum) - ceramic idiophone research neighbor.
• [udu](../udu) - slip-cast ceramic vessel and dual Helmholtz reference.
• [tongue-drum](../tongue-drum) - idiophone documentation done bar.

License

[MIT](LICENSE) - see LICENSE for details.

family-spec.csv

Project artifact.

photo-shotlist.md

Project artifact.

Ceramic Hang Photo Shotlist

Purpose

Capture enough photos to support the README, capstone deck, visual BOM, print packet, and build-log site.

Shot List

risks.md

Project artifact.

Ceramic Hang Risks